2001 SUZUKI GRAND VITARA ect

DIFFERENTIAL (FRONT) 7E-5
4WD Control System Circuit Inspection
Voltage check
Check for input or output voltage (voltage between each circuit and body ground) of ECM (PCM) with ECM
(PCM) connector connected and ignition switch turned ON.
TER-
MINALCIRCUITWIRE
COLORNORMAL
VOLTAGECONDITION
E61-19 4WD Indicator lampORN/
BLK10 –14 V Transfer shift lever : 2H or N
0 – 1 V4 seconds after transfer shift lever shifted
to 4H or 4L
C51-1-9Air pump assembly
(Pump motor and release
valve)RED 0 – 1 V Transfer shift lever : 2H or N
10 – 14 V1 seconds after transfer shift lever shifted
to 4H or 4L
C51-3-7 4WD switchBLK/
ORN10 – 14 V Transfer shift lever : 2H or N
0 – 1 V Transfer shift lever : 4H or 4L
C51-3-17 GroundBLK/
ORN 0 – 1 V –
C51-3-18Air pump assembly
(pressure switch)PNK 0 – 1 V Transfer shift lever : 2H or N
10 – 14 V4 seconds after transfer shift lever shifted
to 4H or 4L
1. ECM (PCM) connector terminal arrangement ; viewed from harness side

7E-6 DIFFERENTIAL (FRONT)
4WD Control System Inspection
1) Install special tool to air hose connecting between air pump
assembly and differential (actuator) as shown in figure.
Tighten adjusting screw (2) of special tool as far as it stops.
Close air check side opening by using fuel hose (1) as blind
plug.
Special tool
(A) : 09918-18110
SUZUKI GENUINE PARTS
(B) : 09367-04002
2) Turn ON ignition switch and shift transfer lever from 2H to 4H
range.
3) Check that motor starts running (a sound can be heard)
within 1 second and it stops when gauge of special tool indi-
cates specified pressure value.
Check also for air leakage.
Air pressure specification
(for 4WD control system inspection) :
30.0 – 45.0 kPa (0.30 – 0.45 kg/cm
2, 4.25 - 6.40 psi)
4) Check that pressure value indicated on gauge of special tool
drops as soon as transfer lever is shifted to 2H position.
5) Start motor by shifting transfer lever to 4H position again.
Loosen adjusting screw (2) to lower pressure value on
gauge. Motor should start to run again and stop in about 4
seconds.
6) With the adjusting screw (2) of special tool loosened, shift
transfer shift lever to N or 2H position and then 4L or 4H
position.
Pump motor should stop about 10 seconds after motor starts
to run. NOTE:
Use care not to bend any part of hose.
3. pipe (to air pump assembly)
4. Hose (to differential carrier)
5. Differential housing

DIFFERENTIAL (FRONT) 7E-9
Front Differential Assembly
DISMOUNTING
1) Lift up vehicle and drain oil.
2) Disconnect air hose and breather hose from differential
housing.
3) Before removing propeller shaft, give match marks (1) on
joint flange and propeller shaft as shown in the figure.
4) Remove propeller shaft flange by removing its 4 bolts and
suspend it with cord or the like.
5) Remove bolts (1) for left mounting bracket and bolts and
nuts (2) for drive shaft flange to set left side of differential
free.
6) Remove bolts (1, 2) and rear mounting bracket (3).
7) Remove bolts (4) and rear mounting bracket No.2 (5).
8) With differential housing assembly held with transmission
jack, remove front mounting bracket (2) bolts (1) on right end
of housing (3). NOTE:
If pull out propeller shaft, transfer oil must be drained
before pulling out.
4 1
2
5
3

DIFFERENTIAL (FRONT) 7E-11
Unit Repair
Refer to the same section of “UNIT REPAIR MANUAL” mentioned in “FOREWORD” of this manual.
Tightening Torque Specification
Special Tool
Fastening partTightening torque
Nm kg-m lb-ft
Front mounting bolts 85 8.5 61.5
Front mounting bracket bolts 50 5.0 36.5
Front drive shaft flange bolts 50 5.0 36.5
Propeller shaft flange bolts 50 5.0 36.5
Rear mounting bolt 85 8.5 61.5
Rear mounting bracket bolts 50 5.0 36.5
Rear mounting bracket No.2 bolts 85 8.5 61.5
09918-18110 09951-16080 09951-26010
Air pressure regulator Bearing installer Bush remover plate

DIFFERENTIAL (REAR) 7F-1
7F
SECTION 7F
DIFFERENTIAL (REAR)
CONTENTS
General Description ........................................ 7F-2
Diagnosis ......................................................... 7F-2
Diagnosis Table ............................................ 7F-2
On-Vehicle Service.......................................... 7F-3
Precaution for Maintenance Service ............. 7F-4
Differential Gear Oil Change ......................... 7F-4
Rear Differential Assembly ............................ 7F-5
Dismounting .............................................. 7F-5
Remounting ............................................... 7F-5
Unit Repair ....................................................... 7F-6Disassembling Unit ....................................... 7F-6
Component Inspection .................................. 7F-9
Sub-Assembly Adjustment and Reassembly 7F-9
Differential carrier .................................... 7F-10
Differential case ...................................... 7F-10
Differential side bearing .......................... 7F-12
Drive bevel pinion.................................... 7F-13
Assembling Unit .......................................... 7F-17
Tightening Torque Specification ................. 7F-20
Required Service Material ............................ 7F-20
Special Tool ................................................... 7F-21

7F-2 DIFFERENTIAL (REAR)
General Description
The differential assembly using a hypoid bevel pinion and gear is installed to the rear axle. It is set in the conven-
tional type axle housing.
The differential assembly is decisive in that the drive power is concentrated there. Therefore, use of genuine
parts and specified torque is compulsory. Further, because of sliding tooth meshing with high pressure between
bevel pinion and gear, it is mandatory to lubricate them by hypoid gear oil.
Diagnosis
Diagnosis Table
Condition Possible Cause Correction
Gear noiseDeteriorated or water mixed lubricant Repair and replenish.
Inadequate or insufficient lubricant Repair and replenish.
Maladjusted backlash between drive bevel pin-
ion and gearAdjust as prescribed.
Improper tooth contact in the mesh between
drive bevel pinion and gearAdjust or replace.
Loose drive bevel gear securing bolts Replace or retighten.
Damaged differential gear(s) or differential pin-
ion(s)Replace.
Bearing noise(Constant noise) Deteriorated or water mixed
lubricantRepair and replenish.
(Constant noise) Inadequate or insufficient
lubricantRepair and replenish.
(Noise while coasting) Damaged bearing(s) of
drive bevel pinionReplace.
(Noise while turning) Damaged differential side
bearing(s) or axle bearing(s)Replace.
Oil leakageClogged breather plug Clean.
Worn or damaged oil seal Replace.
Excessive oil Adjust oil level.

DIFFERENTIAL (REAR) 7F-3
On-Vehicle Service
1. Universal joint flange 9. Differential carrier assembly 17. Bearing adjuster 25. Bolt
2. Hypoid gear set 10. Differential pinion 18. Lock plate 26. Bolt
3. Bevel pinion spacer
Apply thread lock cement
99000-32110 referring to
“DIFFERENTIAL CASE” in
this section.11. Differential gear 19. Pinion shaft No.2 27. Differential case screw :
Apply thread lock
cement 99000-32110 to
thread part of bolt.
4. Shim 12. Pinion shaft No.1 20. Pinion joint Do not reuse.
5. Rear bearing 13. Differential left case 21. Spring washer Tightening torque
6. Front bearing 14. Differential right case 22. Washer Apply differential oil.
7. Oil seal :
Apply grease 99000-25010
to oil seal lip.15. Thrust washer 23. Bevel gear bolt :
Apply thread lock
cement 99000-32110
to thread part of bolt.
8. Flange nut :
After tightening nut so as
rotation torque of bevel pin-
ion shaft to be in specified
value, caulk nut securely.16. Differential side bearing 24. Bolt

7F-4 DIFFERENTIAL (REAR)
Precaution for Maintenance Service
•When having driven through water, check immediately if
water has entered (if so, oil is cloudy). Water mixed oil must
be changed at once.
•Whenever vehicle is hoisted for any other service work than
oil change, also be sure to check for oil leakage and status of
breather hoses.
Differential Gear Oil Change
1) Before oil change or inspection, be sure to stop engine and
lift up vehicle horizontally.
2) Check oil level and existence of leakage. If leakage is found,
correct its cause.
3) Drain old oil and pour proper amount of gear oil as specified
(roughly up to level hole).
4) Torque drain plug (3) and level/filler plugs (2) to specification.
“A” : Sealant 99000-31110
Tightening torque
Differential oil level/filler plug (a) :
50 N·m (5.0 kg-m, 36.5 lb-ft)
Differential oil drain plug (b) :
28 N·m (2.8 kg-m, 20.5 lb-ft)
Hypoid gear oil :
API GL-5, SAE 75W-85, 80W-90 or 90
Oil capacity :
2.5 liters (5.3/4.4 US/Imp. pt.) NOTE:
Hypoid gear oil must be used for differential.
It is highly recommended to use SAE 80W-90 viscosity.
1. Breather hose